Diffused flexible led linear light assembly

ABSTRACT

A diffused flexible LED linear light assembly ( 100 ) includes a flexible LED linear light component ( 102 ) having a flexible base ( 104 ) with individual LEDs ( 106 ) spaced longitudinally along the direction of the component ( 102 ). A partially translucent housing ( 120 ) houses the flexible LED linear light component ( 102 ). A curved section ( 124 ) of the translucent housing ( 120 ) varies in thickness in its lateral surfaces. The thickness may be varied so as to allow a relatively higher percentage of light transmission in areas of weakest LED output strengths. This light output intensity through the translucent housing, in view of the thickness variation, is substantially even or constant circumferentially and radially through the translucent section ( 124 ) of the translucent housing ( 120 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims priority of U.S. patentapplication Ser. No. 15/615,257 filed on Jun. 6, 2017, which claimspriority of U.S. patent application Ser. No. 14/467,384, now issued asU.S. Pat. No. 9,695,991, filed on Aug. 25, 2014, which claims priorityof U.S. Provisional Patent Application Ser. No. 61/872,139 filed Aug.30, 2013.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

REFERENCE TO A “SEQUENCE LISTING,” TABLE OR COMPUTER PROGRAM LISTINGAPPENDIX

Not Applicable.

BACKGROUND OF THE INVENTION Field of the Invention

The invention relates to lighting configurations and, more particularly,to configurations primarily used as decorative assemblies in the form offlexible LED linear lights with diffusion properties.

Background Art

Various types of electrical lighting systems have been known anddeveloped throughout the years since the early days of Edison'sinventions. Originally, most electrical lighting (in the form of lightbulbs and the like) existed for functional and generally practical uses,namely to provide illumination in what would otherwise be relativelydark spatial areas. As electrical lighting development matured,alternatives to conventional light bulbs were the subject of numerousinventions and other developments. For example, and is apparent in manyretail establishments, fluorescent lighting was developed. Fluorescentlamps or tubes are typically relatively low pressure mercury-vapor gasdischarge lamps which use fluorescence to produce visible light.Electrical current in the gas excites mercury vapor which producesshort-wave ultraviolet light. It then causes a phosphor coating on theinside of the bulb to fluoresce, thereby producing visible light.Fluorescent lighting typically converts electrical power into usablelight much more efficiently than incandescent lamps.

Although fluorescent lighting is used in both retail and commercialestablishments, they have some disadvantages. Often, fluorescent lightfittings are relatively bulky, and inconvenient for use in restrictedspaces such as display cases and the like. Also, such light fittings canhave a relatively short life and require frequent maintenance. Stillfurther, fluorescent lighting can operate at a somewhat hazardous highvoltage, with respect to the requirements of a starter/ballast.

Fluorescent lamps and gas discharge lamps have existed for a significantperiod of time, originally being displayed by Tesla in 1893 at the WorldColumbian Exhibition. In 1897, Nernst invented and patented hisincandescent lamp, based primarily on solid state electrical lights.

Other significant developments occurred throughout the 20th century. In1901, Peter Hewitt demonstrated a mercury vapor lamp. In 1981, Philipsfirst marketed what was characterized as compact fluorescent energysaving lamps, with integrated conventional ballast. In 1985, Osram, incompetition with Philips, started to market an electronic energy savinglamp. Shortly thereafter, the “white” sodium vapor lamp was introduced.

Other developments included ceramic metal halide lamps (originallydeveloped by a team at Nela Parc in 1992). In 1994, T-5 lamps having acool tip were introduced and became the most popular fluorescent lamps,with what was considered to be excellent color rendering. Also developedin this timeframe was the first commercial sulfur lamp.

In addition to the foregoing developments, Nick Hollnyak is creditedwith developing the first practical spectrum Light Emitting Diode (LED)in 1962. However, in fact, the general LED has been around, at least ata theoretical level, since initially discovered back in the first decadeof the 20th century.

Hollnyak is typically credited as the father of the modern LED. An LEDcan generally be defined as a semi-conductor light source. When an LEDis switched on, electrons are able to recombine with holes within thedevice, releasing energy in the form of photons. This effect is commonlyreferred to as electroluminescence and the color of the light isdetermined by the energy gap of the semi-conductor. LEDs present manyadvantages over incandescent light sources, including lower energyconsumption, longer lifetime, improved physical robustness, smallersize, and faster switching. LEDs have been used in numerousapplications, as diverse as aviation lighting, digital microscopes,automotive lighting, advertising, general lighting, and traffic signals.Their high switching rates are also useful in advanced communicationstechnology.

One use for LED configurations which has become more popular during thelast several years is the application of LEDs for lighting fixtureswhich may provide some functional illumination, but also may primarilyact as decorative lighting assemblies. LED configurations which areuseful for decorative lighting assemblies are rigid LED linear lightsand flexible LED rope lights, including both indoor and outdoorapplications. Rigid LED lights comprise LEDs conventionally mounted on astructure which links the LEDs together both electrically andphysically. A housing surrounding the LED strip often consists of arigid PVC material. These rigid light strings are typically mountedthrough adhesive backings to the desired structures. In contrast, and inaccordance with the invention as described in the section titled“Detailed Description of the Preferred Embodiments” and defined in thesection titled “Claims”, the invention relates to a “flexible LED linearlight assembly” which utilizes a series of spaced apart and electricallylinked LEDs which are mounted on a flexible printed circuit board. Inaddition to the flexible printed circuit board, the flexible LED linearlight assembly further consists of a flexible housing or lens, asopposed to the use of any type of rigid housing. Further, with flexibleLED linear light assemblies in accordance with the invention, the LEDsmay be surface mounted to a flexible polymer PCB. In contrast, flexibleLED rope lights are assembled such that the LEDs are often attached totwo buss wires.

Flexible LED linear lights in accordance with the invention can beutilized in many applications. For example, flexible LED linear lightsin accordance with the invention can be applied as indoor lighting foroutlining the edges of a kitchen counter, under-lighting baseboards in amovie theatre and similar applications. Flexible LED linear lights canalso be utilized as outdoor lighting, including staircase lighting,outdoor patio or deck lighting, signage and outdoor artistic displays.Flexible LED linear lights are also suitable for use around a garden,pool, driveway, shed or the like. In addition, during holiday seasons,flexible LED linear lights in accordance with the invention can bereadily used to create artistic messages or designs utilizing differentcolors and patterns.

One issue which arises with respect to the use of LEDs, and particularlya string of LEDs, relates to the concept that individual LEDs areeffectively unidirectional hard-point light sources. Accordingly, an LEDlight string, standing alone, can exhibit both dark zones and “hotspots.” It should be mentioned at this point that hot spots are notevident with the use of either florescent or neon tube lights. However,in other lighting assemblies which may be used, for example, as “undercabinet” lighting, hot spots can often show up on the counter top.Correspondingly, in wall wash lighting, the hot spots can show up asirregularities in the light patterns. Such hot spots have become more ofa problem as LED brightness has increased in commercial products. Toovercome these problems of LED hot spots, dark zones and overall lighttransmission uniformity, the LED lighting assembly can include adiffusion apparatus. The concept of diffusion for lighting apparatusrelates to the transmission or reflection of electromagnetic radiationin the form of light, where the radiation is scattered in a number ofdifferent directions, and not totally reflected or refracted. Suchactivity is also referred to as “scattering” of light. The diffusion canalso be referred to as a reflection or refraction of light (or otherelectromagnetic radiation) from an irregular surface or an erraticdispersion through a surface or other medium. Some of the assemblieswhich currently exist use what is characterized as “uniformity tape,”which is a microstructured thin-shell mechanism for mixing and diffusingthe light generated by the LEDs. It is particularly utilized in edge-litdigital displays, including monitors, televisions and signage. In thesesystems, light generated by the LEDs is attempted to be spread evenly toall parts of a display by a light guide, which may typically consist ofa plate of polymethyl methacrylate. This guide transports light by totalinternal reflection, commonly referred as “TIR.” Extraction patterns onthe surface of the light guide will mete out the light and generate auniform brightness distribution. However, even with the light guide,dark zones can be noticeable along the injection edge closest to theLEDs. Further, and somewhat obvious, dark zones will also influence thespacing between LEDs, which limits the ability of designers to reducethe number of LEDs in a display, despite what would exist as far as costadvantages and increased energy efficiency. Further, light-mixing ofcertain known light guides makes digital displays highly sensitive tovariations in LED color and brightness. Still further, closely packedLEDs can also create thermal management issues.

In addition to issues associated with uniformity of diffusion for LEDlight strings and similar assemblies, issues also exist with respect tofacilitating manufacture of diffused LED light strings. For example, themanufacturing process should preferably facilitate assembly of the LEDlight strings in positions desired within a housing comprising, forexample, a translucent housing material. In addition, one problem whichhas existed in known assemblies relates to the fact that various LEDlighting assemblies utilizing flexible LED light strings also utilizeend cap structures which secure the ends of elongated housing andprovide entry of electrical power into the housing interior forconnection with the light string. During the manufacturing process, itis sometimes difficult to appropriately mount the end cap structure tothe ends of the housing, with respect to their interfaces. For example,with certain mounting processes, areas which could be characterized as“steps” or other non-linear or non-continuous edges or other projectionscan be formed between the housing structure and the end cap structures.These formations can increase the difficulty of properly mounting theend cap structures to the housing, and can also take away from theoverall aesthetics of the diffused light string assembly.

With the foregoing issues in mind, reference is now made to a number ofpatents and patent application publications which are associated withLED strings, translucent housing members and/or other optical andelectrical principles. For example, the commonly assigned U.S. PatentApplication Publication to VanDuinen et al., 2012/0170258, is directedto displays of case lighting having a lens with integrally formedfeatures on its interior for purposes of mechanically retaining LEDunits within the interior. At least one of the LED units consists of abase and diodes mechanically engaged on a rigid PCB with integrallyformed features of the lens. An electrical connector is provided toconnect the LED units to a power source. At least one end capincorporates the electrical connector. For purposes of sealing theassembly, a boot seal is provided for sealing the electrical connectorand a plug cover is used to cover any unused electrical connectors whichmay be provided. An adhesive is used to secure the end cover to the lensand seal the connection therebetween. With this configuration, thelighting assembly is suitable for use in wet or potentially explosiveenvironments.

Turning to other specific patent references, a number of the referencesteach general concepts associated with the use of LED light stringswithin translucent housing members. For example, the Cleaver et al. U.S.Pat. No. 8,322,883, discloses an illumination device having a rod-likemember with a light receiving surface and a light-emitting surface. Anelongated light source extends along a position adjacent to a lightreceiving surface of the member, such that the light entering the memberfrom the elongated light source and through the light receiving surfaceis scattered. This scattering process causes a light intensity patternwhich appears substantially uniform along the light-emitting surface ofthe rod-like member. The Cleaver et al. patent is specifically directedto neon lighting, and has relevance only with respect to its discussionof point light sources and advantages of providing a light intensitypattern which appears substantially uniform along a light-emittingsurface of a rigid rod-like member.

The Ikeda U.S. Pat. No. 7,253,444, is directed to a structure andprocess for manufacturing the structure which consists of a casing foruse with a light-emitting unit. Ikeda discloses the concept of the unithaving a substrate and light-emitting diodes housed within the casing.When silicone is injected through an injection opening, the siliconeflows through the entirety of the housing, and then overflows from adischarge opening. The purpose for the silicone injection is to “pushoutside” air or air bubbles which have formed within the light-emittingunit.

The U.S. Patent Application Publication to Ishibashi et al.,2013/0107526 is directed to the use of cluster boards, with a series ofLEDs mounted in an array on central parts of the boards in a transversedirection of the boards. The LED mounting portions in the first andsecond boards are formed so as to be bendable.

The U.S. Patent Application Publication to Mostoller et al.,2010/0201239 is directed specifically to an end cap configuration for alight tube having a LED light string. The end cap assembly includes anend cap connector extending from the body and holding contacts withfirst mating portions configured so as to be electrically connected tothe circuit board, and second mating portions configured to electricallyconnect to the socket connector. The end cap assemblies of Mostoller etal. do not provide for any flush mounting of the cap with an outersurface of the housing profile.

The Goto U.S. Pat. No. 7,045,971, is directed to an illuminatingapparatus having full-color LEDs, with a controller and power supplycable. The light emitting unit includes a series of light emittingelements having different emission colors. Other than showing a stringof full-color LEDs for decorative purposes, the Goto patent does notappear to have any significant relevance.

The U.S. Patent Application Publication to Kelly, et al., 2008/0007945is directed to a cabinet illuminator having a pair of LED lines. The LEDlines are found in an elongated body having a heat transfer portion forconduction of heat from the LEDs to the outer surface of the body. Anengagement configuration exists in the ends of the body for engagementwith other structural members of a display cabinet. The end connectorsdo not appear relevant to the ITC invention.

The Terada, et al., U.S. Pat. No. 7,758,230, discloses a spreadilluminating apparatus having an LED, with a transparent resin plate anda light reflecting sheet. The plate includes slits adapted to have flapportions of the light reflecting sheet inserted therein. An adhesivetape with flexibility is placed along at least one flat portion of thereflecting sheet, so as to cover at least one slit of the resin plate.The light reflecting sheet is prevented from warping or undulating inspite of the difference in thermal expansion coefficients between thematerials of the resin plate and the reflecting sheet. Light emittedfrom the LED and traveling in the resin plate is totally reflected bythe flat portions, and thereby prevented from leaking from the outerside surfaces of the resin plate.

Other references include the following:

-   -   The U.S. Patent Application Publication to Berger, et al.,        2009/0073692 is directed to a modular and expandable lighting        system.    -   The U.S. Patent Application Publication to Payne, 2008/0159694        is directed to a lens configuration for optical touch systems.    -   The Shimura, et al., U.S. Pat. No. 7,815,359, is directed to a        spread illuminating apparatus utilizing a transparent resin        plate.    -   The Terada, et al., U.S. Pat. No. 7,726,868, is directed to a        spread illuminating apparatus, and is primarily related to a        method of injection molding for the transparent resin plate.    -   The Kawakami U.S. Pat. No. 7,160,019, is directed to a        side-lighting surface light source device, along with a        manufacturing method for the same. The device includes a light        source, reflective member, and light guide plate.

The following patents are directed to various types of display devicesutilizing LED configurations.

-   -   Song, et al., Publication No. 2013/0082989;    -   Kawaguchi, et al., U.S. Pat. No. 8,134,675;    -   Myburgh, U.S. Publication No. 2004/0228135.

Other patents utilizing LED string apparatus include the following:

-   -   Sadwick, et al., U.S. Pat. No. 7,709,292;    -   Rawson, et al., U.S. Pat. No. 3,984,923;    -   Aronson, et al., U.S. Pat. No. 4,488,237;    -   Brand, U.S. Pat. No. 5,266,123;    -   Brand, U.S. Pat. No. 5,363,865;    -   Myburgh, U.S. Pat. No. 6,827,472;    -   Wood, U.S. Pat. No. 4,159,490;    -   Bettis, 2004/0184288;    -   Yoshida, et al., 2013/018352;    -   Tsai, et al., U.S. Pat. No. 7,768,658.

SUMMARY OF THE INVENTION

In accordance with the invention, a light assembly is adapted for use asan LED-based source of light for utilitarian and/or decorative purposes.The light assembly includes an elongated flexible LED linear lightcomponent with a series of spaced-apart LEDs supported on a flexiblebase. The assembly also includes a flexible translucent housing or lenswhich has an elongated configuration for laterally enclosing theflexible LED linear light component. At least a portion of the housingforms a section having translucent properties. Further, a thickness ofthe translucent section of the translucent housing may be varied incross section. This variation allows for corresponding variation in thepercentage of light transmission. The variation in light transmissiondepends on the thickness of the translucent section of the housing atany given position. For example, a user may wish to have a light outputintensity through the translucent housing which is substantially even orconstant circumferentially and radially through the translucent sectionof the housing or lens. In this case, the designer can structure thelight assembly where by varying the thickness of the translucentsection, a relatively higher percentage of light transmission can beachieved in areas of weakest LED output strength. With such a variation,the light output intensity through the housing is substantially even orconstant circumferentially and radially throughout the section of thetranslucent housing or lens. However, it should be emphasized that otherthickness variations can be utilized, without departing from certain ofthe principal concepts of the invention.

The translucent housing can include a housing wall having a firstthickness from an interior apex located on an inner surface of thetranslucent housing, and extending perpendicular to the plane of thehousing wall from the interior apex through the housing wall. Thisperpendicular extension occurs on an axis AA which is perpendicular to aplane of the LEDs. The housing wall of the translucent section decreasesin thickness as the angle formed by the plane of the LEDs in a straightline drawn from the plane of the LEDs through the translucent housingwall also decreases.

In accordance with another concept of the invention, a method isprovided for manufacturing the light assembly described in the priorparagraphs herein. The method includes pulling the flexible LED linearlight component through an extrusion of material which composes thetranslucent housing. A channel is then constructed within an interior ofthe translucent housing formed by two inwardly directed projectionsadjacent a bottom inside of the housing.

In accordance with still further concepts of the invention, the lightassembly is sized so that a plane of the LEDs is spaced a distance IHfrom an interior apex located on an inner surface of the translucenthousing. This distance is measured from the LEDs along an axis AA whichis perpendicular to the plane of the LEDs. The translucent housinglaterally encloses an internal gap between the LEDs and the innersurface of the translucent housing. The internal gap is filled with airor silicone gel. Further, the distance IH is of a sufficient size sothat intersecting ray patterns from light rays generated by adjacentones of the LEDs can exhibit combination and interference prior tocontacting the inner surface.

Still further, the change in transmissibility from the air or siliconefilled gap to materials composing the translucent housing, incombination with the scattering of the light rays through reflection andtransmission, causes a diffusion pattern of light intensity to besubstantially even or constant along an axial length of the flexible LEDlinear light component and the translucent housing. Still further, therelative dimensions of the translucent housing, the internal gap, thedistance IH and the spacing of adjacent ones of LEDs is such that darkzones and hot spots are substantially eliminated for resultant lightviewed external o the translucent housing.

In accordance with other concepts of the invention, the light assemblyincludes end means for enclosing the elongated flexible LED linear lightcomponent at a lead end and a trailing end. The end means can include anend cap lead end and an end cap trailing end. In addition, the assemblycan include electrical conductive means connected to the flexible LEDlinear light component and a source of electrical power. The electricalconductive means can include a pair of electrical pigtails connectedbetween the flexible LED linear light component and the electrical powersource.

In addition, the end cap lead end can include one or more apertures forreceiving the electrical conductive means from the electrical powersource, and permitting entrance into an interior of the translucenthousing for electrical connection to the flexible LED linear lightcomponent.

The light assembly can be characterized as having a translucent housingwith a curved section having the translucent properties. The housingalso includes a base section which is integral with the translucentsection, but does not transmit any light rays from the LEDs.

Still further, the end cap lead end and the end cap trailing end eachhave an inner projection for purposes of anchoring and securing therespective end cap to the translucent housing. The end caps arestructured and the inner projections are sized so that each of the endcaps is mounted flush with an outer surface of the translucent housingprofile, without steps or other discontinuities between the outersurfaces of the end caps and the outer surface of the translucenthousing. The translucent housing can also include a pair of inwardlydirected projections adjacent a bottom inner area of the translucenthousing. These projections form a channel that provides the capabilityof locating the flexible LED linear light component against a flatportion of the housing.

In accordance with further concepts of the invention, each of the innerprojections includes a semi-circular cross-sectional profile, having acurved or arcuate shape. The shape corresponds to a shape of the innersurface of the translucent housing to which the inner projection isadhered. Each of the end caps can be sealed with the flexibletranslucent housing through the use of an adhesive having waterresistant and UV-stable properties. The end caps can be further sealedto the flexible translucent housing through the use of a coatingmaterial suitable for bonding and sealing the assembly. Further, each ofthe inner projections can be of an arcuate shape having a beveledterminal end.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described with respect to the drawings, inwhich:

FIG. 1 is a left-side perspective view of a partial length of a diffusedflexible LED linear light assembly in accordance with the invention;

FIG. 2 is a right-side perspective view of the diffused flexible LEDlinear light assembly shown in FIG. 1, but further showing a partialinterior of the flexible LED linear light assembly, with FIG. 2 showingone end of a translucent housing, with an end cap omitted from the endof the housing, and therefore partially showing an interior of thetranslucent housing, with the flexible LED linear light located againstthe bottom of the “D-shaped” translucent housing, and further showing apair of opposing inner projections which serve to locate the flexibleLED linear light within a channel formed by the two opposingprojections;

FIG. 3 is a perspective view of the flexible LED linear light assemblyshown in FIG. 1, showing one of the end caps, and further with theomission of the translucent housing structure;

FIG. 4 is an end view of the translucent housing structure, with theflexible LED linear light positioned therein, and specifically showingthe variation in the thickness of the translucent portion of the housingstructure in a cross-section taken along an axial direction;

FIG. 5 is a plan elevation view of the diffused flexible LED linearlight assembly illustrated in FIGS. 1-4;

FIG. 6 is a partial plan view of the diffused flexible LED linear lightassembly shown in FIG. 5, but specifically showing the flexible LEDlinear light, individual LEDs, and connector cables to an external powersource;

FIG. 7 is a sectional end view of the diffused flexible LED linear lightassembly shown in FIG. 5, taken along section lines 7-7 of FIG. 5;

FIG. 8 is an upper, perspective view of the end cap lead in;

FIG. 9 is an elevation view of the end cap lead in shown in FIG. 8, asviewed from the interior of the diffused flexible LED linear lightassembly, and looking outwardly toward the interior face of the end caplead in;

FIG. 10 is a sectional, side view of the end cap lead in shown in FIG.9, taken along section lines 10-10 of FIG. 9;

FIG. 11 is an underside perspective view of the end cap trailing end ofthe diffused flexible LED linear light assembly shown in FIGS. 1-4;

FIG. 12 is an underside elevation view of the end cap trailing end shownin FIG. 11;

FIG. 13 is an end, elevation view of the end cap trailing end shown inFIG. 11;

FIG. 14 is an end view of the end cap trailing end shown in FIG. 11, asviewed from the exterior of the diffused flexible LED linear lightassembly, and as further shown in an upside down configuration;

FIG. 15 is a sectional, side view of a portion of the end cap trailingend shown in FIG. 12, and taken along section lines 15-15 of FIG. 12;

FIG. 16 is a further side, sectional view of the trailing end end capshown in FIG. 12, taken along section lines 16-16 of FIG. 12, andeffectively showing a side, sectional view of the end cap trailing endfrom an opposing direction of the side, sectional view shown in FIG. 15;

FIG. 17 is a perspective view of the translucent housing of the diffusedflexible LED linear light assembly as shown in FIGS. 1-4;

FIG. 18 is a side, elevation view of the translucent housing shown inFIG. 18;

FIG. 19 is a sectional, end view of the translucent housing shown inFIG. 18;

FIG. 20 is a partial schematic drawing illustrating several of the LEDelements and their circuit connections to an external power source, asthey are associated with the flexible LED linear light; and

FIG. 21 is an enlarged view of the electrical pigtails shown in FIG. 6,which electrically connect the flexible LED linear light to an externalpower source.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The principles of the invention are disclosed, by way of example, in adiffused flexible LED linear light assembly 100 as illustrated in FIGS.1-21 and disclosed in the following paragraphs. As described in thesection of this Application titled “Background Art,” LED rope orflexible LED linear lights are relatively well known and commerciallyavailable for a number of purposes, particularly including decorativelighting systems. A problem which exists with respect to the use of LEDrope or flexible LED linear lights relates to the fact that they canexhibit both dark zones and “hot spots.” The hot spots have become moreof a problem as LED brightness increases. To reduce the problemsassociated with LED hot spots and dark zones, many LED lightingassemblies include diffusion apparatus. However, even with no diffusiontechniques, uniformity is still very difficult to achieve along an axiallength of an LED string. Further, in view of LED lights effectivelyexisting as point sources, photometric profiles of conventional LEDstypically exhibit a bell-shaped intensity graph, centered on the LEDdevice center. It is thus advantageous to achieve higher percentages oflight transmission in areas of relatively “weak” LED output strengths.If this can be achieved, light output can be generated in a manner suchthat intensity is substantially even or constant in a radial orcircumferentially direction around the LED array. In addition toachieving uniformity, the designer may wish to achieve other functions,where uniformity is not necessarily the goal, but instead a certainother type of light transmission pattern is desired to be achieved. Inknown flexible LED linear light systems, other problems can exist withrespect to both manufacturing methods and overall structure with respectto interfaces between elements of the flexible LED linear light andother physical elements, such as end caps and the like. For example,with flexible LED linear lights used for decorative purposes, it isadvantageous if the “lines of design” for such systems are relativelysmooth and textured. Accordingly, care needs to be taken to avoid, forpurposes of aesthetics, jagged or discontinuous edges and interfacesbetween the flexible LED linear light system components. In addition tothe foregoing, it should be mentioned that a consistent cross sectionalshape for the entirety of the axial length of the flexible LED linearlight allows for uniform containment for mounting in channel-shapedholders. It also reduces the size of through passages required formounting in partitioned cabinets and the like.

With the foregoing in mind, the diffused flexible LED linear lightassembly 100 solves or otherwise significantly overcomes theafore-described problems associated with known flexible LED linear lightsystems. Turning to the diffused flexible LED linear light assembly 100,and with reference first and primarily to FIGS. 1-7, the diffusedflexible LED linear light assembly 100 includes what can becharacterized as a flexible LED linear light component 102. The basicdesign of a flexible LED linear light comprises a series of electricallyconnected LEDs mounted on a flexible printed circuit board (or “PCB”).In addition to the flexible printed circuit board, the flexible LEDlinear light also includes a flexible translucent housing or lens whichessentially encases the flexible LED linear light printed circuit board.

It should also be mentioned that prior to the substantive development ofLEDs, “incandescent linear light” was known and used for variousapplications which required a flexible and out of sight light source.However, in view of the advancement of LED technology, incandescentlinear light has essentially become obsolete.

The flexible LED linear light component 102 illustrated in the drawingscomprises an elongated and generally rectangular flexible base 104, withindividual LEDs 106 spaced longitudinally along the elongated directionof the component 102. Each of the LEDs is in the form of a conventionaldiode configuration. FIG. 20 is a relatively simplified schematicdiagram of the circuitry of the LEDs 106. If desired, the LEDs 106 mayinclude a flexible polymer-based printed circuit board, where the LEDs106 are mounted on the base 104 for a relatively low profile design andsmall, but efficient size. The base 104 and LEDs 106 may be manufacturedin various lengths and widths, so as to accommodate the desired heightand sizing of the flexible LED linear light assembly 100.

In addition to the base 104 and the LEDs 106, the flexible LED linearlight component 102 can also be characterized as including or otherwisebeing connected to a pair of electrical connectors, commonly referred toas “pigtails.” The electrical pigtails utilized with the light assembly100 are illustrated as they are connected to the flexible LED linearlight component 102 in FIGS. 5 and 6. These pigtails are also primarilyfunctionally shown in FIG. 20 as being interconnected between the LEDs106 and an external source of electrical power 110. In addition, theelectrical pigtails 108 are expressly shown in a stand-aloneconfiguration in FIG. 21. Each of the pigtails 108 is shown as having aprotective cable or sheath 112 surrounding and encasing conductive wiresof connectors 114. The portion of the conductive wires 114 which areexposed are formed by “stripping back” the cable sheaths 112 from thewires 114. One end of the wires 114 will be connected to one end of thestring of LEDs 106 through the base 104. The other ends of theconductive wires 114 will be connected to the external source forelectrical power 110 shown in FIG. 20. As an alternative, a miniaturesurface mounted connector could also be utilized as a means to providethe electrical connection, should the need arise.

In addition to the LED tape component 102 and the electrical pigtails108, the diffused flexible LED linear light assembly 100 furthercomprises a partially translucent housing 120 which is utilized to houseand encase the flexible LED linear light component 102, as well as oneset of ends of the electrical pigtails 108. For purposes of brevity indescription, the “partially translucent housing” 120 will be referred toherein as the “translucent housing.” In addition to housing and encasingthe flexible LED linear light component 102 and one set of ends of theelectrical pigtails 108, the translucent housing 120 also serves tofunction as a partially translucent lens for the light emitted from theLEDs 106 of the flexible LED linear light component 102. Still further,the translucent housing 120 functions so as to exhibit a certain levelof diffusion of the light emitted from the LEDs 106. The overall shapeand structure of the translucent housing 120 is shown in various figuresof the drawing, including FIGS. 1, 2, 4, 5, 7 and 17-19. The translucenthousing can be constructed of a number of different materials, includinga flexible polymer such as silicone 535U.

With reference particularly to FIGS. 2, 4, 7 and 19, the translucenthousing 120 comprises one “side” which can be characterized as a flatbase section 122. The flat base section 122 can be of an opaqueformulation and, given the positioning of the LEDs 106, does not exhibitany translucent properties. With reference to the positioning shown inFIG. 4 in cross-sectional configuration, extending upwardly from bothsides of the flat base section 122 is a translucent curved section 124.The curved section 124, along with the base section 122, completes alateral enclosure of the flexible LED linear light component 122.

In accordance with certain concepts of the invention, the curved arcuatesection 124 of the translucent housing 120 varies in thickness (in across-sectional configuration) in its lateral surfaces. The variation inthicknesses along the curved section 124 is particularly shown in FIGS.4, 7 and 19. For purposes of description of these thickness variations,FIG. 4 shows the curved arcuate section 124 as being divided amongvarious segments along the housing 120. Specifically, FIG. 4 first showsa pair of base connecting segments 126, which could be characterized asbeing connected to or otherwise integral with the ends of the flat basesection 122 and depending upwardly (as viewed in FIG. 4) therefrom.These base connecting segments 126 can be relatively constant withrespect to thickness. Again with respect to the viewing direction ofFIG. 4, extending upwardly from the base connecting segments 126 aresegments 128. The segments 128 are illustrated on FIG. 4 as extendingalong the outer surface of the housing 120 for a distance A. As furthershown in FIG. 4, the thickness of the segments 128 vary and increasefrom the upper portion of the base connecting segments 126 to what isshown in FIG. 4 as the upper portions of segments 128. For purposes ofthe description, the average thickness of each of the segments 128 canbe characterized as thickness X. Although not of an absolute necessityin accordance with the invention, the segment 128 shown on the left sideof FIG. 4 can essentially be a mirror image of the segment 128 shown onthe right side of FIG. 4. Accordingly, each of these segments 128 has alength along the housing surface of A, with an average thickness of X.Again, it is emphasized that the references to these various segmentsand thicknesses are solely for purposes of description, and the actualtranslucent housings 120 in accordance with the invention do notnecessarily have any structural differentiation among these segments,other than the relative relationships with respect to housingthicknesses.

Extending upwardly from the top of each of the segments 128 are furthersegments which can be characterized as segments 130. As again shown inFIG. 4, the segments 130 extend upwardly along the curved arcuatesection 124 of the housing 120, and are illustrated in FIG. 4 as havinga segment length B. Again for purposes of the description, the averagethickness along the length B of the segments 130 can be characterized asthickness Y. In accordance with the invention, the average thickness Yof the segments 130 will be greater than the average thickness X of thesegments 128.

Continuing with reference to FIG. 4, the translucent curved arcuatesection 124 of the translucent housing 120 includes a segment 132 whichextends upwardly from the upper portions of segments 130 and interfaceswith each of the upper portions of segments 130. The segment 132,consisting of the “uppermost” portion of the translucent housing 120, isshown in FIG. 4 as having a length C along the surface of the housing120. For purposes of description of the invention, the segment 132 canbe characterized as having an average thickness Z. In accordance withthe invention, the average thickness Z will be greater than the averagethickness Y which, in turn, was previously described herein as beinggreater than the average thickness X.

The foregoing description using what can be characterized as onlyimaginary or “representative” segments and average thicknesses of thehousing 120 serves to illustrate one of the principal concepts of theinvention. The LEDs 106 and the elongated base 104 are positioned withinthe interior of the translucent housing 120 as particularly shown inseveral of the drawings, including FIGS. 1 and 7. With thisconfiguration, and assuming that the thickness of the translucentsection 124 of the housing 120 was uniform along its circumference inthe axial direction, the intensity of the light transmitted to theinterior surface of the translucent section 124 would be greatest at thecenter of segment C, corresponding to a direction to which isperpendicular to the transmitting plane of each of the LEDs 106. Thatis, the intensity of the light of the LEDs 106 as it impinges on theinterior surface of the translucent section 124 is greatest along whatis shown as axis AA, or axis 134 in FIG. 4. Further, in accord with thissame concept, the photometric profile of each of the LEDs 106 willtypically form a bell-shaped array which is centered along axis AA andwill be of an approximately 120 degree included angle. That is, as theangle of the LED light rays move away from the perpendicular angleformed by axis AA (i.e., the light ray angle moves from the area ofsegment C to the areas of segments B and A), the natural light intensityof each of the LEDs 106 will decrease. This can result in a significantdisadvantage with respect to the aesthetics of the resultant lightdistribution outside of the flexible LED linear light assembly. Further,to the extent that the flexible LED linear light assembly 100 is beingused in a functional manner so as to provide light for a practicalpurpose, the drop off of light intensity away from axis AA also is asignificant disadvantage.

To overcome these problems, the translucent housing 120, as particularlyshown in FIGS. 4 and 7, is constructed with the thickness of the housing120 varying along the areas corresponding to segments A, B and C.Preferably, the thickness variation curve is relatively “smooth” and“steps” or other irregularities in the photometric profile curve are notexhibited. In accordance with the foregoing, the average thickness Z ofsegment C shown in FIG. 4 will be greater than the average thickness Yof each of the segments B. Correspondingly, the segments A will have anaverage thickness X which is less than the average thickness Y and theaverage thickness Z. By appropriately varying the foregoing thicknessesof the translucent housing 120 in cross section, a higher percentage oflight transmission through the body of the translucent housing willoccur within segments A, as compared to the percentage of lighttransmission allowed to pass through the translucent housing 120 at thelocations of segments B. In turn, the percentage of light transmissionallowed to pass through the translucent housing 120 in the areas ofsegment C will be less in percentage than the percentages oftransmission in segments B and A. With these differences in thepercentages of light transmission through the thicknesses of housing120, it is therefore possible to generate and provide for a uniformintensity of the LED light output throughout the transmission areacorresponding to the 120 degree included angle. That is, it has beenfound that by varying the thickness of the housing 120 in cross section,higher percentages of light transmission in areas having the relatively“weakest” LED output strength is achieved. The light output can then begenerated with a strength which causes the output to be substantially“even” or “constant” in a circumferential direction, along the axialdirection of the flexible LED linear light component 102.

To achieve an appropriate uniformity of light intensity along the axiallength of the translucent housing 120, reference is made to the interiorstructure of the area encased by the translucent housing 120. This areais illustrated in FIG. 4 as interior 140. This interior 140 can becharacterized as having an “interior height IH” as also shown in FIG. 4.This interior height IH, which is also characterized as interior height152, extends from what could be characterized as the LED base level 156which essentially exists on the same level as the uppermost lens portionof each of the LEDs 106. This interior height IH then extends upwardlyin a perpendicular direction relative to the plane of the LEDs 106, tothe interior apex 154. This interior apex 154 can be characterized asthe uppermost position of an inner surface 142 of the translucenthousing 120. In accordance with certain novel concepts of the invention,the open interior 140 is filled with air or a silicone gel 158, again asshown in FIG. 4. If the interior height IH is of a sufficient value, andassuming that the contours of an inner surface 142 have a curvaturesubstantially corresponding to the curvature shown in FIG. 4, asignificant change in “transmissibility” from the air or silicone gel tothe translucent housing material will be existent. Further, with thesufficiency of the interior height IH, and appropriate positioning ofadjacent LEDs 106, the intersecting ray patterns from the adjacent LEDscan combine and interfere with each other. That is, under theseappropriate circumstances, the ray patterns can cause both combinationand interference of the light rays. Interference is well known and is aphenomenon in which two rays will superimpose and form a furtherresultant wave of greater or lower amplitude. This type of interferenceusually refers to the interaction of waves that are correlated orcoherent with each other, either because they came from the same sourceor, as in this case, because they have the same or nearly the samefrequency. Such intersecting ray patterns readily form combining waves.With the appropriate dimensions regarding interior height IH and thespacing of the individual LEDs 106, the resultant intersecting raypatterns from the adjacent LEDs can combine and interfere prior tohitting the inner surface 142 of the translucent housing 120. Inaccordance with all of the foregoing, the change in transmissibilityfrom the air or silicone to the housing material, plus the lightscattering occurring through reflection and transmission will cause thediffusion pattern of the light to be extremely even or constant acrossthe axial length of the LED component. With this phenomena occurring,the diffusion pattern is extremely even or constant across the entiretyof the axial length of the LED stream. This occurrence virtuallyeliminates the well-known “hot spots” which are often created byindividual LEDs which are used in strips where there are relativelysmall distances between the LEDs without the gap or open interior 140formed by the appropriate dimensions and the use of air or silicone gelas a “fill” for the interior of the translucent housing 120. The generalconcepts associated with hot spots were previously discussed in detailin the section entitled “Background Art” of this application. Again, andin accordance with the invention, the size of the open interior 140, andparticularly the size of the interior height IH, in combination with theopen interior being filled with air or silicone gel, results in thediffusion pattern for the LED light intensity to be extremely even orconstant along the axial length of the flexible LED linear lightcomponent 102. This diffusion pattern, which essentially eliminates hotspots created by the individual LEDs 106, results from both the changein transmissibility from the air or silicone gel within the openinterior 140 to the translucent housing 120, in combination with thesufficiency of the interior height IH.

It should be emphasized that the foregoing description of the thicknessvariations for the housing 120 corresponds to certain embodiments inaccordance with the invention. In accordance with certain generalaspects of the invention, the designer may wish to obtain a diffusionpattern which is not necessarily an attempt to provide uniformity oflight intensity in radial and circumferential directions. Instead, thedesigner may wish to obtain other patterns. In accordance with theinvention, the designer can achieve light intensity variation anddiffusion variation by other variations in thicknesses of thetranslucent housing, in the radial and/or circumferential directions.

Turning to other aspects of the diffused flexible LED linear lightassembly 100 in accordance with the invention, the assembly 100 furtherincludes a pair of end caps, comprising an end cap lead end 170 and anend cap trailing end 190. The end cap 170 is illustrated in FIGS. 1, 3and 5-7 in combination with the translucent housing 120. Further, theend cap 170 is shown in detail in a stand-alone configuration in FIGS.8, 9 and 10. Correspondingly, the end cap trailing end 190 is shown indetail in a stand-alone configuration in FIGS. 11-16. The end caps 170and 190 are fitted on the ends of the translucent housing 120, and areused to enclose and encase the flexible LED linear light component 102within the lower portion of the interior 140 of the housing 120.Further, as described in subsequent paragraphs herein, the trailing endend cap 190 includes means for permitting the electrical pigtails 108 tobe received through the end cap 190 for providing electrical powerbetween the external source 110 and the flexible LED linear lightcomponent 102.

Turning first to the end cap lead end 170 and with specific reference toFIGS. 8, 9 and 10, the end cap 170 provides a sealed connection with thetranslucent housing 120. The end cap 170 includes an outer body 172, asprimarily shown in FIGS. 8 and 9. As particularly shown in FIG. 9, theouter body 172 includes a curved section 174 and a lower flat section176. The section 174 and section 176 are preferably integral with eachother. Of particular importance, the outer body 172 is sized andconfigured so as to essentially “match” the cross sectionalconfiguration of the translucent housing 120. With respect to the outerbody 172, the body 172 comprises an outer face 178, primarily shownpartially in FIG. 3 and in FIG. 10. On an opposing side of the outerface 178, the outer body 172 includes a hollow interior area 180, againshown primarily in FIGS. 8, 9 and 10.

In accordance with certain concepts of the invention, the end cap 170further includes an inner projection 182. The inner projection 182 isshown in FIGS. 8 and 9, and also shown in the sectional view of FIG. 10.The inner projection 182, as apparent from the drawings, is of anarcuate shape with a partially beveled end 184 at the terminal portionof the projection 182. The inner projection 182 is sized and configuredso as to be received within the curved or arcuate section 124 of thetranslucent housing 120. In fact, the translucent housing 120 and theend cap 170 are particularly sized and configured so that the innerprojection 182 abuts the inner surface 142 of the housing 120. Thisconfiguration is particularly shown in FIG. 7. With reference to bothFIGS. 5 and 7, the end cap 170 is sealed with the translucent housing120 through the use of an adhesive 186. The adhesive 186 can be any of anumber of commercially available adhesives suitable for bonding thematerials. Also, glues or similar sealing agents, which are preferablywater resistant and UV-stable can be utilized. For further sealing ofthe end cap 170 to the translucent housing 120, coating material 188having a silicone base (see FIGS. 5 and 7) can be utilized. With thisconfiguration, and again with the appropriate sizing of the variouselements, the end cap 170 is secured to the translucent housing 120 in amanner so that the end cap 170 mounts flush with the outer surface ofthe translucent housing profile. This configuration is in contrast toone where a “step” or other discontinuity is formed, which would occurif the end cap 170 was located “outside” of the profile of thetranslucent housing 120. This flush-type configuration between thetranslucent housing 120 and an end cap is particularly shown in FIG. 1with respect to the translucent housing 120 and the end cap trailing end190. With this configuration utilizing the inner projection 182 andproviding for a flush mounting between the end cap 170 and thetranslucent housing 120, the mounting of the end cap 170 is facilitatedand made easier for the assembler. In addition, the aesthetics of theoverall diffused flexible LED linear light assembly 100 aresignificantly improved, relative to a configuration where the end cap isnot flush mounted with the housing.

The end cap trailing end 190 will now be described, primarily withrespect to FIGS. 1, 3, 5, 7 and 11-16. It should be noted that thetrailing end end cap 190 is substantially similar in sizing andconstruction to the end cap lead end 170, but with certain additionalelements primarily related to providing means for receiving theelectrical pigtails 108. More specifically, the end cap 190, like theend cap 170, includes an outer body 192, as primarily shown in FIGS. 11,12, 15 and 16. As particularly shown in FIG. 11, the outer body 192includes a curved section 194 and a lower flat section 196. The section194 and section 196 are preferably integral with each other.

Of particular importance, the outer body 192 is sized and configured soas to essentially “match” the cross-sectional configuration of thetranslucent housing 120. With respect to the outer body 192, the body192 comprises an outer face 198, primarily shown in FIGS. 1 and 14. Onan opposing side of the outer face 198, the outer body 192 includes ahollow interior area 200, primarily shown in FIGS. 3, 11 and 13.

In accordance with certain concepts of the invention, and similar to theend cap lead end 170, the end cap 190 further includes an innerprojection 202. The inner projection 202 is particularly shown in FIGS.3, 11-13 and 16. The inner projection 202, as apparent from thedrawings, is of an arcuate shape with a partially beveled end 204 at theterminal portion of the projection 202. The inner projection 202 issized and configured so as to be received within the curved or arcuatesection 124 of the translucent housing 120. In fact, the translucenthousing 120 and the end cap 190 are particularly sized and configured sothat the inner projection 202 abuts the inner surface 142 of the housing120. This configuration is shown in FIG. 7. With reference to both FIGS.5 and 7, the end cap 190 is preferably sealed with the translucenthousing 120 through the use of the adhesive 186 previously describedwith respect to end cap 170. For a further sealing of the end cap 190 tothe translucent housing, coating material 188 having a silicone base(see FIGS. 5 and 7) can be utilized. With this configuration, and againwith the appropriate sizing of the various elements, the end cap 190 issecured to the translucent housing in a manner so that the end cap 190mounts flush with the outer surface of the translucent housing profile.This configuration is in contrast to one where a “step” or otherdiscontinuity is formed, which would occur if the end cap 190 waslocated “outside” of the profile of the translucent housing 120. Thisflush-type configuration between the translucent housing and the end cap190 is particularly shown in FIG. 1. In accordance with the invention,and with this configuration utilizing the inner projection 202 andproviding for a flush mounting between the end cap 190 and thetranslucent housing 120, the mounting of the end cap 190 is facilitatedand made easier for the assembler. In addition, the aesthetics of theoverall diffused flexible LED linear light assembly 100 aresignificantly improved, relative to a configuration where the end cap isnot flush mounted with the housing.

As earlier stated, the end cap trailing at 190 is substantially similarto the end cap lead end 170. One distinction relates to the end cap 190having means for receiving elements for connecting the flexible LEDlinear light component 102 to the previously described external sourceof electrical power 110. Specifically, and as particularly shown inFIGS. 1, 3, and 11-16, the end cap trailing end 190 includes a pair ofconnection apertures 208. The connection apertures 208 are utilized toreceive the electrical pigtails 108 which were previously describedherein with respect to FIG. 20, and provide components for purposes oftransmitting electrical power from the external source of electricalpower 110 to the flexible LED linear light component 102. Theseconnection apertures 208 are not an absolute necessity for the end caplead end 170, but could be provided if required for purposes of“stringing together” a number of flexible LED linear light assemblies100.

Another concept associated with the invention relates to the interiorstructure of the translucent housing 120. As previously described, thetranslucent housing 120 includes an open interior area 140, as shown,for example, in FIGS. 2, 4, 7 and 19. Below the open interior area 140is an area within the translucent housing 120 which is referred to inthe drawings as hidden area 144. This hidden area 144 is also shown inFIGS. 2, 4, 7 and 19. The open interior area 140 and the hidden area 144are formed and separated by a pair of inwardly directed projections 146.These inwardly directed projections 146 are formed integrally with thetranslucent housing 120 as the lower portion of the translucent curvedor arcuate section 124. These projections 146 are shown as the firstinner projection 148 and second inner projection 150. These innerprojections form a channel 210 which separates the open interior area140 from the hidden area 144. By adding the channel 210 formed by theinwardly directed projections 146, and by locating the projections onthe bottom inside portion of the translucent housing 120, it is thenpossible to locate the flexible LED linear light component 102 securelyagainst the bottom of the flat base section 122.

To form the translucent housing 120 with the inwardly directedprojections 146, a method of manufacture is utilized whereby theflexible LED linear light component 102 is essentially “pulled” throughan extrusion of the translucent housing material. As earlier stated, thechannel formed by the projections 146 provides the capability oflocating the flexible LED linear light component 102 on the bottomportion of the housing 120. This method of manufacture facilitatesassembly, while also “setting” the geometry for a successful air orsilicone gel filled gap as described in previous paragraphs.

It will be apparent to those skilled in the pertinent arts that otherembodiments of flexible LED linear light assemblies in accordance withthe invention can be designed. That is, the principles of flexible LEDlinear light assemblies in accordance with the invention are not limitedto the specific embodiment described herein. Accordingly, it will beapparent to those skilled in the art that modifications and othervariations of the above-described illustrative embodiments of theinvention may be effected without departing from the spirit and scope ofthe novel concepts of the invention.

1. A method of forming a flexible LED linear light assembly, the methodcomprising: providing at least a portion of an outer housing of aflexible linear light assembly, wherein the outer housing includes afirst sidewall, a second sidewall, a curved portion extending betweenthe first and second sidewalls, and a channel formed between the firstand second sidewalls; providing a flexible linear light component havinga plurality of LEDs; moving the outer housing and the flexible linearlight component through an extrusion to position the flexible linearlight component within the channel
 2. The method of claim 1, wherein thechannel is formed by a pair of inwardly directed projections extendinginward from the first and second sidewalls toward one another.
 3. Themethod of claim 2, wherein the outer housing includes a base positionedbetween the first and second sidewall.
 4. The method of claim 3, whereinthe linear light component is positioned between the inwardly directedprojections and the base.
 5. The method of claim 1, wherein thethickness of the curved portion of the outer housing is varied along atleast a segment of the curved portion.
 6. The method of claim 5, whereinsaid thickness of said translucent section of said translucent housingis varied in cross-section so as to allow light transmission in areas ofweakest LED output strength.
 7. The method of claim 1, wherein movingthe outer housing and the flexible linear light component through anextrusion comprises simultaneously moving the housing and flexiblelinear light component through an extrusion.
 8. The method of claim 1,wherein the curved portion of the outer housing is translucent.
 9. Alight assembly adapted for use as an LED-based source of light forutilitarian and/or decorative purposes, said light assembly comprises:an elongated flexible LED linear light component having a plurality ofspaced-apart LEDs supported on a base; a translucent housing having anelongated configuration for laterally enclosing said flexible LED linearlight component, said housing or lens have at least a portion thereofforming a section having translucent properties; end means for enclosingsaid elongated flexible LED linear light component at a lead end and atrailing end, said end means comprising an end cap lead end and an endcap trailing end; each of said end caps comprises an inner projectionfor purposes of anchoring and securing the respective end cap to saidtranslucent housing; and said end caps are structured and said innerprojections are sized so that each of said end caps is mounted flushwith an outer surface of said translucent housing profile, without stepsor other discontinuities between the outer surfaces of the end caps andthe outer surface of the translucent housing.
 10. The light assembly ofclaim 9, characterized in that said inner projections are formedintegral with an outer wall of said end cap corresponding to saidparticular inner projection.
 11. The light assembly of claim 9,characterized in that each of said inner projections comprises asemi-circular cross-sectional profile, having a curved or arcuate shape,said shape corresponding to a shape of said inner surface of saidtranslucent housing to which said inner projection is adhered.
 12. Thelight assembly of claim 9, characterized in that each of said end capsis sealed with said flexible translucent housing through the use of anadhesive having water resistant and UV-stable properties.
 13. The lightassembly of claim 9, characterized in that each of said end caps isfurther sealed to said flexible translucent housing through the use of acoating material suitable for bonding and sealing the assembly.
 14. Thelight assembly of claim 9, characterized in that each of said innerprojections is of an arcuate shape having a beveled terminal end. 15.The light assembly of claim 9, characterized in that at least of one ofsaid end caps comprises one or more apertures for receiving electricalconductive means from a source of electrical power and into saidtranslucent housing for electrical connection to said flexible LEDlinear light component.